Styrenated-unsaturated oil modified alkyd, drying oil, and a phenol-styrene oxide resin coating composition



Patented May 27, 1952 UNITED STATE s PATENT OFFICE STYRENATED-UNSATURATED OIL MODI- FIED ALKYD, DRYING OIL, AND A PHE- NOL-STYRENE OXIDE RESIN COATING COMPOSITION 3 Claims.

This invention relates to improved coating compositions readily prepared from inexpensive and abundantly available raw materials. More particularly the invention relates to self drying film forming compositions involving styrenated alkyd resins and styrene oxide phenolic condensation products.

The paint and varnish industry has been seeking to adapt styrene to coating composition uses because of its low cost and general availability. Many useful coating compositions have been prepared but are not of general utility because of their brittleness and because of the difficulty of avoiding incompatibility with more conventional varnish ingredients. This incompatibilty tends to reduce the strength of the film, increase its susceptibility to water and alkali, as well as to produce opaque coatings. It is also known that transparent drying oil substitutes can be prepared from styrene by interpolymerizing it with unsaturated alkyd resins by specialized procedure.

7 Compounds of this type are commercially available and are known to the industry as styrenated alkyd resins. Although for many purposes the available styrenated alkyd resins are useful, there vide new transparent coating compositions from styrene and related monomers. A further purpose is to provide a coating composition having unusual resistance to thermo-softening and to the action of organic solvents, water and alkali.

The expression styrenated alkyd, as used in the protective coating industry and in this specification, means a copolymer of an unsaturated alkyd and a styrene type of monomer, such as styrene, a-methylstyrene, vinylbiphenyl, and isopropenylbiphenyl. The unsaturated alkyd resins are polyester condensation products involving the unsaturated natural drying oil acids, aliphatic polyhydroxy compounds, polycarboxylic acids, and in some cases saturated monocarboxylic acids. acids derived from saponification of linseed oil, soy oil, China-wood oil, dehydrated castor' oil, oiticia oil, and similar drying and semi-drying oils, and includes oleic acid, linoleic acid, linolenic acid, eleostearic acid, geranic acid, sorbic acid, palmitolic acid, and humeroceric acid. In the preparation of the alkyd resins useful polyhydroxy aliphatic compounds are any of the glycols, such as ethylene glycol, diethylene glycol, triethylene glycol, higher polyethylene glycol and mixtures thereof, the propylene glycols and polypropylene glycols, the higher glycols, such as tetramethylene glycol, hexamethylene glycol and decamethylene glycol, glycerol, sorbitol, mannitol, erythritol and pentaerythritol. Useful car- Suitable natural drying oil acids are the I boxylic acids for the alkyd preparation are the phthalic acid, maleic acid, succinic acid, fumaric acid, adipic acid and itaconic acid, and. the anhydrides of the cis-dicarboxylic acids. As is conventional in the alkyd preparation art, monocarboxylic acids, such as benzoic acid and salicylic acid, and monohydric alcohol, such as benzoyl and butyl alcohol may be used to terminate the polyester chains.

The styrenated alkyd resins are prepared by first forming the alkyd resin which can be initiated by reacting glycerol with a natural drying oil or with natural drying oil'acids, the proportions of reactants being such that the monoglyceride is formed in either case, which is then reacted with polybasic acid and if desired with more glycerol or other polyhydroxy alcohol to produce a final alkyd composition with an acid number between 0 and 20. The initial stage may utilize any of the polyhydroxy alcohols in place of the glycerols, any of the well known polycarboxylic acids as cross-linking agents, and any monocarboxylic acid or alcohol to terminate polyester chains and reduce the average molecular weight of the polyester. The alkyd so formed is a transparent, viscous liquid composition and will have little or no coloration.

The alkyd resins prepared in accordance with the preceding paragraph are then copolymerized with styrene, preferably in the presence of a suitable peroxy catalyst, which is soluble in the mixed monomer, for example benzoyl peroxide, acetyl peroxide, t-butyl hydroperoxide, hydrogen peroxide, or isopropylpercarbonate, or in the polymerization medium. From 0.01 to 5 percent by weight of the peroxide (based on the monomer) may be used.

Several methods are known to be useful in the preparation of the styrenated alkyd resins. If desired the reaction may be conducted in the presence of an inert solvent or diluent, such as xylene, benzene, toluene, dioxane, or petroleum ether at reflux temperature, and adding the styrene type monomer gradually until a reaction mass of pre-determined viscosity is effected, the end-point viscosity being that which will yield a desired viscous liquid copolymer after evaporation of the inert solvent or diluent.

An alternative method of preparing the styrenated alkyd resin, heating a mixture of the alkyd resin and the vinyl or isopropenyl aromatic hydrocarbon and heating them until the monomers are copolymerized to the desired extent as determined by the measured viscosities.

In the United States Patent 2,422,637, issued June 1'7, 19 47, to Charles A. Thomas, there is described and claimed a resinous composition suitable for the preparation of varnishes by dissolution in drying oils. The resinous composition is made by condensing styrene oxide with phenol 'other p-alkylphenol; having upto six carbon atoms in the alkyl radical.

The styrene oxide-phenol .e ondensation Q.

is prepared by heating the phedolifi canstitne t and graduallyadding a readily desired quantity of arylalkylene oxide, f or exarnple from 50 1 9 200 percent by weight or the eem-1. min .one to four hours being required for the addition. "The temperature required will bejrom 1 20" C."to about 225? C.,, precautions being taken to keep-thereaction rate under control, a rapid but not vigorous reaction has been found to produce the :best :ree sult. 'After the completion of the reaction furi he tih tine at. minced n es ures assis in the item. at @Qnemerseand wat "rmdnced the ;;nolymen .ii n act Itahasbeenioriddifihni w itin rnreparaizien. n1 slear, 1 transparen :suriaee films nf .qua ty.,.m y hememated :zby disselying stx ena d alkyd r s n -t-he mesins prepar d loy- Qndensithe analky en oxide phenolic resins. Useful 'ooating .compositions'anay he prepared by utilizing is to .90 percent lay Weight of either eompmient. but the most desirable :nmdu ts ar prepa d h us n imm -A-to 69j19ereent 91f seen-component. J nempnsitiensi ay :be .nren b blendl wrin mymgJ-on solntiqns er th st renexi iz :rfli mrliesimand the dtyrenated alkydresin, i01- lexamnlezfnom @netp. ten ,glifiilits :Qf "ithfi .styrena ted .alkydiresin and. filth-.93? i=0 tenfpa s of --tl e styrene onideenh o1 -=be dis er n nne It!) i enpartsof. thmlrin oi-l V e new varnishes may he dried ii-air but lmfifilflmied fi yi szmayi-bexinduaedi h at in V 1a :-.sieitahle.air eireiilatipn eyen o zz n tne sinn 'flmflei inirared lamps. .dcne e iat dmoom tempeisflifiured Fl/illfi may be ach eved y the .insummation .of :conventianal ldr ers tor exam l the lead, cobalt and manganesenaphthenates or similar nears me a salt oldred-nlms are required .cmventional dyes and p m nt may be added. fihe seating summation may also be Hey the inns: oration of conventional 'simzentsnsuolms:turnsntinamin m spir ts coa 7 star. mi hthaand nylenazthe;qflantii adietermlined readily brine determ nation of the vi s-r I nesity r quir d *fQ IIlB pa t u ar m th d of .appiieationxcontemmat d f 5 Further details of the preparation and use of the new varnishes are set forth w th esp .sto :the-iellowin sneeifie examp e.

h Emmn 1 d n ,oil soluble phenolformaldehy de resin was I disso-lyed in tung oil in the proportions of one hundred pounds of resin for 30 gallons of oil, :by

and heating at 500? for twenty minutes. The v-iscous'solution :so :producedewas then thi rmed by adding an equal Weight ofqamixture of 80 percent mineral spirits and nercent xylene. A similar phenolic was p pared' an .identiea'l manner except that styreneoxidephenol :used place of the phenoliormaldehyde. :Each gof the two Phenolic resins 'was.--hlended;in :variousproportions with a "fillie-lahore etahnilnliionslemonsimtes men-say mnatedalkyds :he'ablended with. nomen- :tinnal phenolic resins. since :innompatible prddnct are produced, but nominations of styrene oxide-phenol nesinsare-miseibleinallproportions with :styrenated alkyd resins Land that the dried films remain clear and transparent. Thus, by practicing..rtnis invention the improvements in solvent, .alkali :and water resistance of astyrenated ,aIkydyarni-shes can foeefiected .WjthOUt :sacrifieing. thaclarity and transparency Bf the resulting films.

The invention is defined 'by the followin claims.

1. A coating eemnosition comprising asoluble .copolymer .of 25 to .percentzby'weight :of a compound of the group nonsisting of styrene, .a-methylstyrene, vimfilbiphenyland isopropenyl- 'biphenyl, .and from 1:75 .to percent .of 11n- -sazturated natural drying acid -modified alkyd resinfhaying an new number ib-etvreenio end .20,- a natural drying ioil and amesin prepared 123 :6811- densing styrene ioxidevand a phenol of I the iormula:

' Where R a radiealoltbe 8911p s nsistin 0f hydrogen and alkyl nadicals ha ing up to six 7 .carbon atoms.

Aeoat n comp. .osition .comprising a soluble qnol mer of irom 254:0- 1 percent by wei ht of styrene and from 1.5 -to".25 percent of an .un- Saturated natural drying oil acid modified alkyd resin hayingnn ,aoid numberhetween .0 and 20, a :natural drying oil and .a. condensation product of phenol and item .50 4:01.200 percent, based on th ph nol. of styrene oxide.

ingoil .acid modified alkyd resin having .an :acid

number from 0 to 2.0, from one .to ,ten par-ts of natural drying oil, and from ,one to ten partslof V a condensation resin .of "phenol .anddfrom 50 .to 200 percent, basedon the phenol, of styrene oxide.

@EFEBENCES .GITED The-following references are of record in the file of this paten-t:

.styrenaiied-alkyd resin containing 0.03 percent 'hy' vei ht of co alt "(as cobalt naph en pg sition dried --tae -i ee inpne hour and s .hlended ami h UNITED .srmrrns .BA'IYENTS Number 'iflame Date 2392577110 WakeiQlid 1612 :al. Jan-8, 1946 21422.53? Thomas 1- m. J1m l7. 19

GTHER REFERENGES lteichjhdld Advertisement in Chem. and "Eng News Vol.26 No. 7, 3111966, July'fi 1948. 

1. A COATING COMPOSITION COMPRISING A SOLUBLE COPOLYMER OF FROM 25 TO 75 PERCENT BY WEIGHT OF A COMPOUND OF THE GROUP CONSISTING OF STYRENE, A-METHYLSTYRENE, VINYLBIPHENYL AND ISOPROPENYLBIPHENYL, AND FROM 75 TO 25 PERCENT OF AN UNSATURATED NATURAL DRYING OIL ACID MODIFIED ALKYD RESIN HAVING AN ACID NUMBER BETWEEN 0 AND 20, A NATURAL DRYING OIL, AND A RESIN PREAPRED BY CONDENSING STYRENE OXIDE AND A PHENOL OF THE FORMULA: 